Automated diagnostics for transport refrigeration units

ABSTRACT

A system for managing transport refrigeration units ( 28 ) is provided. The system includes a storage device ( 80 ) to store transport parameters ( 82 ) associated with a transport refrigeration unit ( 28 ). The storage device storing historical transport parameters ( 84 ) for other transport refrigeration units ( 28 ). Also included is an equipment management system ( 90 ) coupled to the storage device, the equipment management system ( 90 ) including: a diagnostic module ( 92 ) to determine a condition of the transport refrigeration unit ( 28 ) in response to the transport parameters ( 82 ); a predictive maintenance module ( 94 ) to determine a need for upcoming maintenance of the transport refrigeration unit ( 28 ) in response to the transport parameters ( 82 ); and a remaining life module ( 96 ) to determine a remaining life of at least one component of the transport refrigeration unit ( 28 ) in response to the transport parameters ( 82 ).

BACKGROUND OF THE DISCLOSURE

The embodiments disclosed herein generally relate to cold chaindistribution systems, and more specifically to an apparatus and a methodfor managing a transport refrigeration unit within a cold chaindistribution system.

Typically, cold chain distribution systems are used to transport anddistribute perishable goods and environmentally sensitive goods (hereinreferred to as perishable goods) that may be susceptible to temperature,humidity, and other environmental factors. Perishable goods may includebut are not limited to fruits, vegetables, grains, beans, nuts, eggs,dairy, seed, flowers, meat, poultry, fish, ice, and pharmaceuticals.Advantageously, cold chain distribution systems allow perishable goodsto be effectively transported and distributed without damage or otherundesirable effects.

Refrigerated trucks and trailers are commonly used to transportperishable goods in a cold chain distribution system. A transportrefrigeration system is mounted to the truck or to the trailer inoperative association with a cargo space defined within the truck ortrailer for maintaining a controlled temperature environment within thecargo space.

Conventionally, transport refrigeration systems used in connection withrefrigerated trucks and refrigerated trailers include a transportrefrigeration unit having a refrigerant compressor, a condenser with oneor more associated condenser fans, an expansion device, and anevaporator with one or more associated evaporator fans, which areconnected via appropriate refrigerant lines in a closed refrigerant flowcircuit. Air or an air/gas mixture is drawn from the interior volume ofthe cargo space by means of the evaporator fan(s) associated with theevaporator, passed through the airside of the evaporator in heatexchange relationship with refrigerant whereby the refrigerant absorbsheat from the air, thereby cooling the air. The cooled air is thensupplied back to the cargo space.

The components of a transport refrigeration unit may be periodicallyinspected and repaired for scheduled maintenance often regardless of theactual utilization on the unit. Further unpredicted unscheduledmaintenance causes unplanned down time of the unit. Improved systems andparticularly improved maintenance prediction would provide both cost andefficiency benefits.

BRIEF DESCRIPTION OF THE DISCLOSURE

According to one embodiment, a system for managing transportrefrigeration units is provided. The system includes a storage device tostore transport parameters associated with a transport refrigerationunit. The storage device storing historical transport parameters forother transport refrigeration units. Also included is an equipmentmanagement system coupled to the storage device, the equipmentmanagement system including: a diagnostic module to determine acondition of the transport refrigeration unit in response to thetransport parameters; a predictive maintenance module to determine aneed for upcoming maintenance of the transport refrigeration unit inresponse to the transport parameters; and a remaining life module todetermine a remaining life of at least one component of the transportrefrigeration unit in response to the transport parameters.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include thediagnostic module activates an alarm when the condition of the transportrefrigeration unit is outside of a selected range of conditions.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include thepredictive maintenance module activates an alarm when the need forupcoming maintenance of the transport refrigeration system isdetermined.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include the remaininglife module activates an alarm when the remaining life of at least onecomponent of the transport refrigeration unit equals a selected value.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include that thestorage device stores a maintenance history of the transportrefrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include that thetransport parameters include parameters of the transport refrigerationunit including at least one of operating temperature, operatingpressure, operating vibrations, operation cycles, and operation durationof the transport refrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include that thetransport parameters include at least one location of the transportrefrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include that thetransport parameters include weather data experienced by the transportrefrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include that thetransport parameters include quality inspections of perishable goodscarried by the transport refrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the system may include that thetransport parameters include manually entered data.

According to another embodiment, a method of managing transportrefrigeration units, the method is provided. The method includesstoring, using a storage device, transport parameters associated with atransport refrigeration unit, the storage device storing historicaltransport parameters for other transport refrigeration units. The methodalso includes monitoring, using an equipment management system, thetransport refrigeration unit, the equipment management system coupled tothe storage device, the equipment management system including: adiagnostic module to determine a condition of the transportrefrigeration unit in response to the transport parameters; a predictivemaintenance module to determine a need for upcoming maintenance of thetransport refrigeration unit in response to the transport parameters;and a remaining life module to determine a remaining life of at leastone component of the transport refrigeration unit in response to thetransport parameters.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include activating analarm, using the diagnostic module, when the condition of the transportrefrigeration unit is outside of a selected range of conditions.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include activating analarm, using the predictive maintenance module, when the need forupcoming maintenance of the transport refrigeration unit is determined.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include activating analarm, using the remaining life module, when the remaining life of atleast one component of the transport refrigeration unit equals aselected value.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include that thestorage device stores a maintenance history of the transportrefrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include that thetransport parameters include parameters of the transport refrigerationunit including at least one of operating temperature, operatingpressure, operating vibrations, operation cycles, and operation durationof the transport refrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include that thetransport parameters include at least one location of the transportrefrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include that thetransport parameters include weather data experienced by the transportrefrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include that thetransport parameters include quality inspections of perishable goodscarried by the transport refrigeration unit.

In addition to one or more of the features described above, or as analternative, further embodiments of the method may include that thetransport parameters include manually entered data.

Other aspects, features, and techniques of the invention will becomemore apparent from the following description taken in conjunction withthe drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the disclosure is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other features and advantages ofthe disclosure are apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a schematic view of a system for managing transportrefrigeration units for use in a cold chain distribution system,according to an embodiment of the present disclosure; and

FIG. 2 illustrates a schematic view a cold chain distribution systemthat may incorporate embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring now to the drawings, FIG. 1 illustrates a schematic view of asystem 10 for managing transport refrigeration units for use in a coldchain distribution system, according to an embodiment of the presentdisclosure. FIG. 2 illustrates a schematic view a cold chaindistribution system 200 that may incorporate embodiments of the presentdisclosure. Typically, transport refrigeration systems 20 are used totransport and distribute perishable goods and environmentally sensitivegoods (herein referred to as perishable goods 34). In the illustratedembodiment, a transport refrigeration system 20 includes anenvironmentally controlled container 14, a transport refrigeration unit28 and perishable goods 34. The container 14 may be pulled by a tractor12. It is understood that embodiments described herein may be applied toshipping containers that are shipped by rail, sea, or any other suitablecontainer, without use of a tractor 12. The container 14 may define aninterior compartment 18.

In the illustrated embodiment, the transport refrigeration unit 28 isassociated with a container 14 to provide desired environmentalparameters, such as, for example temperature, pressure, humidity, carbondioxide, ethylene, ozone, light exposure, vibration exposure, and otherconditions to the interior compartment 18. In further embodiments, thetransport refrigeration unit 28 is a refrigeration system capable ofproviding a desired temperature and humidity range. The perishable goods34 may include but are not limited to fruits, vegetables, grains, beans,nuts, eggs, dairy, seed, flowers, meat, poultry, fish, ice, blood,pharmaceuticals, or any other suitable cargo requiring cold chaintransport.

In the illustrated embodiment, the transport refrigeration system 20includes sensors 22. The sensors 22 may be utilized to monitor transportparameters 82 internal and external to the container 14. The transportparameters 82 monitored by the sensors 22 may include but are notlimited to temperature, pressure, humidity, carbon dioxide, ethylene,ozone, light exposure, vibrations, and other conditions in the interiorcompartment 18. Accordingly, suitable sensors 22 are utilized to monitorthe desired parameters. Advantageously, sensors 22 may be selected forcertain applications depending on the perishable cargo to be monitoredand the corresponding environmental sensitivities. In an embodiment,temperatures are monitored. In certain embodiments, a user desires tomaintain and monitor temperatures or other parameters within anacceptable range. As seen in FIG. 1, the sensors 22 may be placeddirectly on the perishable goods 34.

Further, as in the illustrated embodiment, sensors 22 may be used tomonitor various transport parameters 82 of the transport refrigerationsystem 20. These sensors 22 may be placed in a variety of locationsincluding but not limited to on the transport refrigeration unit 28, ona door 36 of the container 14 and throughout the interior compartment18. The sensors 22 may be placed directly within the transportrefrigeration unit 28 to monitor the performance of the transportrefrigeration unit 28. Individual components internal to the transportrefrigeration unit 28 may also be monitored by sensors 22 to detectperformance aspects, such as, for example usage cycles, duration,temperatures and pressure of individual components. As seen, the sensors22 may also be placed on the door 36 of the container 14 to monitor theposition of the door 36. Whether the door 36 is open or closed affectsboth the temperature of the container 14 and the performance of thetransport refrigeration unit 28. For instance, in hot weather, an opendoor 36 will allow cooled air to escape from the container 14, causingthe temperature of the interior compartment 18 to rise, which createsadditional stress on the transport refrigeration unit 28 by forcing thetransport refrigeration unit 28 to work harder to cool the interiorcompartment 18. Additionally, the global positioning system (GPS)location may also be detected by the sensors 22. The GPS location mayhelp in providing information from other data sources 40 regarding localweather 42 (including solar gain) experienced by the container 14 alongthe travel route. The local weather 42 affects the temperature of thecontainer 14 and thus affects the operation on the transportrefrigeration unit 28. For instance, the transport refrigeration unit 28may have to work harder on a container 14 travelling through a desertthat is exposed to long period of heat and solar gain.

As illustrated in FIG. 1, the transport refrigeration system 20 mayfurther include, a controller 30 configured to log a plurality ofreadings from the sensors 22, known as transport parameters 82, at aselected sampling rate. The controller 30 may be enclosed within thetransport refrigeration unit 28 or separate from the transportrefrigeration unit 28 as illustrated. The transport parameters 82 mayfurther be augmented with time, position stamps or other relevantinformation. The controller 30 may also include a processor (not shown)and an associated memory (not shown). The processor may be but is notlimited to a single-processor or multi-processor system of any of a widearray of possible architectures, including field programmable gate array(FPGA), central processing unit (CPU), application specific integratedcircuits (ASIC), digital signal processor (DSP) or graphics processingunit (GPU) hardware arranged homogenously or heterogeneously. The memorymay be but is not limited to a random access memory (RAM), read onlymemory (ROM), or other electronic, optical, magnetic or any othercomputer readable medium.

In an illustrated embodiment, the transport refrigeration system 20 mayinclude a communication module 32 in operative communication with thecontroller 30 and in wireless operative communication with a network 60.The communication module 32 is configured to transmit the transportparameters 82 to the network 60 via wireless communication. The wirelesscommunication may be, but is not limited to, radio, microwave, cellular,satellite, or another wireless communication method. The network 60 maybe but is not limited to satellite networks, cellular networks, cloudcomputing network, wide area network, or another type of wirelessnetwork. The communication module 32 may include a short rangeinterface, wherein the short range interface includes at least one of: awired interface, an optical interface, and a short range wirelessinterface.

Transport parameters 82 may also be provided by other data sources 40,as illustrated in FIG. 1. These other data sources 40 may be collectedat any point throughout the cold chain distribution system 200, which asillustrated in FIG. 2 may include harvest 204, packing 206, storageprior to transport 208, transport to distribution center 210,distribution center 212, transport to display 214, storage prior todisplay 216, display 218 and consumer 220. These stages are provided forillustrative purposes and a distribution chain may include fewer stagesor additional stages, such as, for example a cleaning stage, aprocessing stage, and additional transportation stages. The other datasources 40 may include, but are not limited to, weather 42, qualityinspections 44, inventory scans 46, and manually entered data 48. Theweather 42, as discussed above, has an effect on the operation of thetransport refrigeration unit 28 by influencing the temperature of thecontainer 14 during transport (e.g. 210 and 214) but the weather 42 alsohas other influences on the transport refrigeration unit 28. Forinstance, the weather 42 prior to and at harvest 204 may have an impacton the quality of the perishable goods 34, which in turn would affecthow hard the transport refrigeration unit 28 must work to preserve theperishable goods 34. Moreover, quality inspections 44, similar to theweather 42, may reveal data of the perishable goods 34 that may affecthow hard the transport refrigeration unit 28 must work to preserve theperishable goods 34. Quality inspections 44 may be done by a machine ora human being. Quality inspections 44 performed by a machine may beaccomplished using a variety of techniques including but not limited tooptical, odor, soundwave, infrared, or physical probe.

Further inventory scans 46, may also reveal information about theperishable goods 34 that may affect how hard the transport refrigerationunit 28 must work to preserve the perishable goods 34. For instance, theinventory scan 46 may reveal a temperature of the distribution center212 where the perishable goods 34 were kept and thus the transportrefrigeration unit 28 must either increase or decrease its output tobring the perishable goods 34 to the correct temperature. While thesystem 10 includes sensors 22 to aid in automation, often times the needfor manual data entry is unavoidable. The manually entered data 48 maybe input via a variety of devices including but not limited to acellular phone, tablet, laptop, smartwatch, a desktop computer or anyother similar data input device.

In the illustrated embodiment, the system 10 further includes a storagedevice 80 to store transport parameters 82 associated with the transportrefrigeration unit 28. The storage device 80 may also store historicaltransport parameters 84 and maintenance history 86 of the transportrefrigeration unit 28. The storage device 80 may be but is not limitedto a random access memory (RAM), read only memory (ROM), or otherelectronic, optical, magnetic or any other computer readable medium.

In the illustrated embodiment, the system 10 further includes anequipment management system 90. As shown, the equipment managementsystem 90 may include a diagnostic module 92, a predictive maintenancemodule 94, and a remaining life module 96. The equipment managementsystem 90 may also include a processor (not shown) and an associatedmemory (not shown). The processor may be but is not limited to asingle-processor or multi-processor system of any of a wide array ofpossible architectures, including field programmable gate array (FPGA),central processing unit (CPU), application specific integrated circuits(ASIC), digital signal processor (DSP) or graphics processing unit (GPU)hardware arranged homogenously or heterogeneously. The memory may be butis not limited to a random access memory (RAM), read only memory (ROM),or other electronic, optical, magnetic or any other computer readablemedium.

The diagnostic module 92 determines a condition of the transportrefrigeration unit 28 in response to the transport parameters 82. Thediagnostic module 92 may detect faults in the transport refrigerationunit 28 and provide an indication of the potential sources for thefault. The diagnostic module 92 may compare the transport parameters 82to thresholds, limits, ranges, etc. to detect faults and then accesshistorical transport parameters 84 to derive one or more potentialsources for the fault. The diagnostic module 92 activates an alarm 100when the condition is, for example, outside of a selected range ofconditions.

The predictive maintenance module 94 determines a need for upcomingmaintenance of the transport refrigeration unit 28 in response to thetransport parameters 82. The predictive maintenance module 94 activatesan alarm 100 when the need for upcoming maintenance of the transportrefrigeration unit 28 is determined. The predictive maintenance module94 may detect patterns in the transport parameters (e.g., patterns ofhigh/low compressor outlet pressure) to predict a failure. Thepredictive maintenance module 94 may also detect trends in the transportparameters 82, compare the transport parameters 82 to thresholds and/ordetermine rates of change of in transport parameters 82 to determine aneed for preventative maintenance. The existence of a series of alarmoccurrences (e.g., over-pressure) may indicate the need for preventativemaintenance.

The remaining life module 96 determines a remaining life of at least onecomponent of the transport refrigeration unit 28 in response to thetransport parameters 82. The remaining life module 96 activates an alarm100 when the remaining life of at least one component of the transportrefrigeration unit 28 equals a selected value. The remaining life module96 may use a baseline life curve which provides remaining life as afunction of time. The baseline life curve may be generated based on thehistorical transport parameters 84. The baseline life curve may beadjusted or shifted in response to events or transport parameters 82.For example, detection of operation under harsh high ambient conditionsmay reduce the remaining life whereas the occurrence of a maintenanceoperation may extend the remaining life.

The diagnostic module 92, predictive maintenance module 94, andremaining life module 96 may utilize historical transport parameters 84from other transport refrigeration units and the maintenance history 86of the current transport refrigeration unit 28 in their determinations.The historical transport parameters 84 may provide information such as,for example, life curves, failure rates, and a selected range ofconditions for each component of the transport refrigeration unit 28.The selected range of conditions may define the normal operatingconditions of component of the transport refrigeration unit 28.Operation outside of the selected range of conditions may indicate anissue with a component of the transport refrigeration unit 28. Themaintenance history 86 may help indicate persistent issues with acomponent of the transport refrigeration unit 28. The maintenancehistory 86 may also help the predictive maintenance module 94 adjust themaintenance schedule of the transport refrigeration unit 28.

The alarm 100 may be an alert sent to a user device 110 such as, forexample, a cellular phone, tablet, laptop, smartwatch, desktop computeror any similar device. The alarm 100 may be an instantaneous alarm or ascheduled alarm for a later time. For instance, the predictivemaintenance module 94 may predict that a component of a transportrefrigeration unit 28 should be scheduled for maintenance in two months,so the predictive maintenance module 94 may schedule the alarm 100 to gooff a little in advance of the newly scheduled maintenance date.Whereas, if the diagnostic module 92 determines that a component of thetransport refrigeration unit 28 is currently outside a select range ofconditions, the diagnostic module 92 may activate the alarm 100immediately to avoid further damage to the component.

Advantageously, as provided herein, the equipment management system 90may help to better predict maintenance schedules and reduce unplanneddown time of the transport refrigeration system. In some embodiments,advantageously, the equipment management system 90 may help inre-routing transport refrigeration systems 20 so they do not embark on ajourney that the transport refrigeration unit 28 cannot complete.

While the disclosure has been described in detail in connection withonly a limited number of embodiments, it should be readily understoodthat the disclosure is not limited to such disclosed embodiments.Rather, the disclosure can be modified to incorporate any number ofvariations, alterations, substitutions or equivalent arrangements notheretofore described, but which are commensurate with the scope of thedisclosure. Additionally, while various embodiments of the disclosurehave been described, it is to be understood that aspects of thedisclosure may include only some of the described embodiments.Accordingly, the disclosure is not to be seen as limited by theforegoing description, but is only limited by the scope of the appendedclaims.

What is claimed is:
 1. A system for managing transport refrigerationunits, the system comprising: a storage device to store transportparameters associated with a transport refrigeration unit and amaintenance history of the transport refrigeration unit, the storagedevice storing historical transport parameters for other transportrefrigeration units, wherein the transport parameters comprise weatherdata experienced by the transport refrigeration unit and at least oneof: an operating temperature of the transport refrigeration unit,operating vibrations of the transport refrigeration unit, an operatingpressure of the transport refrigeration unit, operation cycles of thetransport refrigeration unit, an operation duration of the transportrefrigeration unit, and a location of the transport refrigeration unit;an equipment management system coupled to the storage device, theequipment management system including: a processor; and a memorycomprising computer-executable instructions that, when executed by theprocessor, cause the processor to perform operations, the operationscomprising: determining a condition of the transport refrigeration unitin response to the transport parameters; determining a need for upcomingmaintenance of the transport refrigeration unit in response to thetransport parameters; determining a remaining life of at least onecomponent of the transport refrigeration unit in response to thetransport parameters; adjusting a maintenance schedule of thetransportation refrigeration unit in response to at least themaintenance history and the need for upcoming maintenance; andre-routing the transport refrigeration unit so that the transportrefrigeration unit does not embark on a journey that the transportrefrigeration unit cannot complete, wherein the weather data experiencedby the transport refrigeration unit includes solar gain experienced byan environmentally controlled container operably associated with therefrigeration unit, the refrigeration unit being configured to controlenvironmental conditions within the environmentally controlledcontainer.
 2. The system of claim 1, further comprising: an alarmconfigured to activate when the condition of the transport refrigerationunit is outside of a selected range of conditions.
 3. The system ofclaim 1, further comprising: an alarm configured to activate when theneed for upcoming maintenance of the transport refrigeration unit isdetermined.
 4. The system of claim 1, further comprising: an alarmconfigured to activate when the remaining life of at least one componentof the transport refrigeration unit equals a selected value.
 5. Thesystem of claim 1, wherein: the transport parameters include thelocation of the transport refrigeration unit.
 6. The system of claim 1,wherein: the transport parameters include quality inspections ofperishable goods carried by the transport refrigeration unit.
 7. Thesystem of claim 1, wherein: the transport parameters include manuallyentered data.
 8. A method of managing transport refrigeration units, themethod comprising: storing, using a storage device, transport parametersassociated with a transport refrigeration unit and a maintenance historyof the transport refrigeration unit, the storage device storinghistorical transport parameters for other transport refrigeration units,wherein the transport parameters comprise weather data experienced bythe transport refrigeration unit and at least one of: an operatingtemperature of the transport refrigeration unit, operating vibrations ofthe transport refrigeration unit, an operating pressure of the transportrefrigeration unit, operation cycles of the transport refrigerationunit, an operation duration of the transport refrigeration unit, and alocation of the transport refrigeration unit; monitoring, using anequipment management system, the transport refrigeration unit, theequipment management system coupled to the storage device, the equipmentmanagement system including: a processor; and a memory comprisingcomputer-executable instructions that, when executed by the processor,cause the processor to perform operations, the operations comprising:determining a condition of the transport refrigeration unit in responseto the transport parameters; determining a need for upcoming maintenanceof the transport refrigeration unit in response to the transportparameters; determining a remaining life of at least one component ofthe transport refrigeration unit in response to the transportparameters; adjusting a maintenance schedule of the transportationrefrigeration unit in response to at least the maintenance history andthe need for upcoming maintenance; and re-routing the transportrefrigeration unit so that the transport refrigeration unit does notembark on a journey that the transport refrigeration unit cannotcomplete, wherein the weather data experienced by the transportrefrigeration unit includes solar gain experienced by an environmentallycontrolled container operably associated with the refrigeration unit,the refrigeration unit being configured to control environmentalconditions within the environmentally controlled container.
 9. Themethod of claim 8, further comprising: activating an alarm when thecondition of the transport refrigeration unit is outside of a selectedrange of conditions.
 10. The method of claim 8, further comprising:activating an alarm when the need for upcoming maintenance of thetransport refrigeration unit is determined.
 11. The method of claim 8,further comprising: activating an alarm when the remaining life of atleast one component of the transport refrigeration unit equals aselected value.
 12. The method of claim 8, wherein: the transportparameters include the location of the transport refrigeration unit. 13.The method of claim 8, wherein: the transport parameters include qualityinspections of perishable goods carried by the transport refrigerationunit.
 14. The method of claim 8, wherein: the transport parametersinclude manually entered data.